System and method for tracking inventory

ABSTRACT

An inventory-tracking unit associated with a storage unit holding items to be dispensed includes a card reader to read an access card issued to a user and a recorder to record data from items removed from the storage unit. A processor communicates with a sensor in the storage unit and with the card reader and recorder. The sensor provides item data to the processor that is associated with items removed from the storage unit. The processor compares item data received from the sensor with the data recorded by the recorder to detect coincidence. The processor generates a transaction upon coincidence of item data received from the sensor with the recorded data. A communications interface transmits the transaction to a remote site.

PRIORITY STATEMENT

This application is a continuation application of U.S. patentapplication No. 12/656,069 filed Jan. 14, 2010 which is a continuationof Application No. 10/853,251, filed on May 26, 2004, and claims theassociated benefit under 35 U.S.C. §120; the entire contents of all ofwhich are incorporated herein by reference.

BACKGROUND

1. Field

The present invention relates generally to inventory management and inparticular to a system and method for tracking inventory and to aninventory-tracking unit.

2. Description of Related Art

Inventory control is a primary concern for product retailers so thatexcess and insufficient inventory situations are avoided. Within amortar and bricks environment, inventory is controlled by countingexisting inventory at physical locations. Controlling inventory in thismanner is however much more difficult and in fact impractical inenvironments where inventory is dispensed through stocked vendingmachines that are distributed over a large geographical area.

To deal with inventory control in these environments, service personnelare dispatched along service routes according to pre-set schedules sothat the vending machines can be checked for inventory levels and properoperation. As will be appreciated, during a service route all vendingmachines along the service route are checked. In many instances, thechecks reveal that the vending machines are operating properly and holdsufficient inventory. As a result, the checks are unnecessary. In otherinstances, the checks reveal that the vending machines havemalfunctioned and/or are depleted of inventory, resulting in potentiallost sales especially if delays exist between checks.

A similar problem exists in the medical supply environment wheremedical, surgical, biological and/or pharmaceutical supplies are storedin refrigeration units distributed throughout medical, research and/oreducational facilities located at different geographical locations. Inthe past, dispatching medical supplies through these refrigeration unitshas been based on the honor system. Users removing supplies fromrefrigeration units are expected to list the removed supplies on chartsposted on the refrigeration units so that supply usage can be trackedand costs assigned in the appropriate manner.

As will be appreciated, inventory control in this medical supplyenvironment suffers similar problems to those encountered in the vendingmachine environment discussed above. Routine checks of all refrigerationunits must be carried out to determine the inventory level and operatingstatus of the refrigeration units. In many cases the checks are eitherunnecessary or late. The latter condition can be particularlyproblematic in the case where a refrigeration unit fails and thetemperature within the refrigeration unit rises to a point where theinventory is spoiled. Inventory shrinkage is also a problem in themedical supply environment. In many instances, users removing suppliesfrom the refrigeration units fail to record accurately the removeditems. As a result, costs for the missing inventory cannot be assigned.As will be appreciated, improvements in inventory control in these typesof environments are desired.

It is therefore an object of the present invention to provide a novelsystem and method for tracking inventory and a novel inventory-trackingunit.

SUMMARY

According to one aspect of the present invention there is provided aninventory-tracking unit associated with a storage unit holding items tobe dispensed comprising:

-   -   a card reader to read an access card issued to a user;    -   a recorder to record data from items removed from said storage        unit;    -   a processor communicating with a sensor in said storage unit and        with said card reader and recorder, said sensor providing item        data to said processor that is associated with items removed        from said storage unit, said processor comparing item data        received from said sensor with data recorded by said recorder to        detect coincidence, said processor generating a transaction upon        coincidence of item data received from said sensor with said        recorded data; and    -   a communications interface to transmit said transaction to a        remote site.

In one embodiment, the communications interface transmits thetransaction over a wireless communications link, the recorder is abarcode scanner, the card reader is designed to read a magnetic stripeon an access card and the storage unit is a refrigeration unit. Ahousing accommodates the card reader, barcode scanner, processor andcommunications interface. The housing is coupled to the storage unit andthe processor is wired to the sensor. During access of the storage unit,the card reader locks the access card therein until the item datareceived from the sensor is coincident with the recorded data.

In one embodiment, the inventory-tracking unit further comprising alocking mechanism coupled to the storage unit to inhibit access to itemsheld therein. The locking mechanism is conditioned by the processor to adisengaged state to permit access to items held in the storage unit whena valid access card is read by the card reader. The processorcommunicates with at least one diagnostic sensor associated with thestorage unit and transmits an alarm event to the remote site in responseto alarm condition input received from the at least one diagnosticsensor.

According to another aspect of the present invention there is providedan inventory-tracking system comprising:

-   -   a remote site; and    -   at least one inventory-tracking unit associated with storage        unit holding items to be sensed, said inventory-tracking unit        comprising:        -   an inventory-tracking unit associated with a storage unit            holding items to be dispensed comprising:        -   a card reader to read an access card issued to a user;        -   a recorder to record data from items removed from said            storage unit;        -   a processor communicating with a sensor in said storage unit            and with said card reader and scanner, said sensor providing            item data to said processor that is associated with items            removed from said storage unit, said processor comparing            item data received from said sensor with data recorded by            said recorder to detect coincidence, said processor            generating a transaction upon coincidence of item data            received from said sensor with said recorded data; and        -   a communications interface to transmit said transaction to a            remote site.

The present invention provides advantages in that the inventory-trackingunit can be easily retrofitted to existing refrigeration units therebyto permit existing refrigeration units to be upgraded so that inventorytherein can be remotely monitored and tracked over a wirelesscommunications link. Since the inventory-tracking unit controls accessto the inventory within the refrigeration unit, distribution ofrestricted inventory can be accurately controlled thereby to inhibitinventory loss through inventory expiry and/or shrinkage.

The present invention also provides advantages in that since inventoryremoved from the refrigeration unit is tracked in real time, inventorywithin the refrigeration unit can be managed to avoid item “sell-out”conditions. Statistical information concerning inventory use can also beeasily generated allowing inventory stocking procedures to be adjustedto meet inventory demand. In addition, if the refrigeration unit suffersa failure and the temperature within the refrigeration unit rises abovea threshold temperature, since the operating state of the refrigerationunit is remotely monitored service personnel can be dispatched quicklyto avoid inventory spoilage.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described more fullywith reference to the accompanying drawings in which:

FIG. 1 is a front elevation view of a refrigeration unit in combinationwith an inventory-tracking unit in accordance with the presentinvention;

FIG. 2 is a front elevation view of the inventory-tracking unit of FIG.1;

FIG. 3 is a left side elevation view of the inventory-tracking unit ofFIG. 1;

FIG. 4 is a right side elevation view of the inventory-tracking unit ofFIG. 1;

FIG. 5 is a rear elevation view of the inventory-tracking unit of FIG.1;

FIG. 6 is a top plan view of the inventory-tracking unit of FIG. 1;

FIG. 7 is a front elevation view of the interior of theinventory-tracking unit of FIG. 1;

FIG. 8 is a block diagram of internal circuitry within theinventory-tracking unit of FIG. 1;

FIG. 9 is a flowchart showing the steps performed by theinventory-tracking unit during accessing of the refrigeration unit;

FIG. 10 is a schematic view of an inventory-tracking system including aninventory-tracking unit that communicates with a remote site over awireless wide area network;

FIG. 11 is a front elevation view of a refrigeration unit in combinationwith a top mounted inventory-tracking unit; and

FIG. 12 is a schematic view of an inventory-tracking system includinginventory-tracking units that communicate with a computer room over awireless local area network.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Turning now to FIG. 1, a refrigeration unit such as a freezer in whichmedical, surgical, biological and/or pharmaceutical supplies(hereinafter referred to as “medical supplies”) are stored, is shown andis generally identified by reference numeral 20. An inventory-trackingunit 30 is coupled to one side of the refrigeration unit 20 to trackinventory removed from the refrigeration unit. The inventory-trackingunit 30 may alternatively be mounted on the top of the refrigerationunit 20 as shown in FIG. 11.

The refrigeration unit 20 for the most part is standard and receivespower from a conventional 120 volt AC power source via an electricalcord. A door light switch is provided in the refrigeration unit 20 tosense when the door of the refrigeration unit is in an open or closedcondition. As is known, when the door of the refrigeration unit 20 isopened, the door light switch closes a circuit causing an internal lightwithin the refrigeration unit 20 to illuminate. An internal sensorantenna of the acoustic or electromagnetic type (not shown) isaccommodated within the rubber seal surrounding the door frame of therefrigeration unit 20 to sense tagged items being placed in or removedfrom the refrigeration unit. A temperature sensor in the form of athermistor is also provided in the refrigeration unit 20 to sense whenthe temperature within the refrigeration unit 20 rises above a thresholdtemperature.

FIGS. 2 to 6 better illustrate the physical layout of theinventory-tracking unit 30. As can be seen inventory-tracking unit 30includes a housing 32 that is secured to the side of the refrigerationunit 20 by a plurality of suitable fasteners (not shown). The front faceof the housing includes a barcode scanner or reader 34, a display 36 anda card reader 38. A spring-loaded solenoid door lock 40 is also providedon the front face of the housing 32 and is actuable to engage anddisengage the door of the refrigeration unit to control entry into therefrigeration unit 20. An antenna 42 is provided on one side of thehousing 32 to allow the inventory-tracking unit 30 to communicate with aremote site over a wireless communication link as will be described.Ventilation holes 44 are provided in the top of the housing 32 to allowair to circulate within the housing 32 thereby to dissipate heat.

Turning now to FIG. 7, the integrated internal physical layout of theinventory-tracking device 30 is illustrated. The inventory-trackingdevice 30 includes a main control board 50 that communicates with thebarcode scanner 34, the display 36, the card reader 38 and the solenoiddoor lock 40. The main control board 50 also communicates with a modem52 that is coupled to the antenna 42 as well as with a multi-drop bus(MDB) board 54. An audio siren 56 is also coupled to the main controlboard 50.

The circuitry on the main control board 50 and the multi-drop bus board54 is illustrated in FIG. 8 and is generally identified by referencenumeral 60. As can be seen, circuitry 60 includes a central processingunit (CPU) 62 having a real-time clock. CPU 62 communicates with amicroprocessor supervisor 64 and with a plurality of interfaces via adatabus 66, namely a card reader interface 68, a radio interface 70, anda freezer interface 72. Card reader interface 68 is coupled to the cardreader 38. Radio interface 70 is coupled to a wide area network (WAN)radio transceiver 74 and/or to a local area network (LAN) radiotransceiver 76. The transceivers 74 and 76 communicate with the antenna42 thereby to permit wireless communications. The freezer interface 72is coupled to the solenoid door lock 40.

CPU 62 further communicates with static random access memory (RAM) 80,flash memory 82 and communications interface 84 via the databus 66. Thecommunications interface 84 communicates with the internal sensorantenna within the refrigeration unit 20. The display 36 is also coupledto the databus 66 and communicates with the CPU 62. An on-board powersupply 86 provides the necessary power for operation of theinventory-tracking unit 30. On-board power supply 86 is coupled to theelectrical cord of the refrigeration unit 20 via an interconnectingharness (not shown). CPU 62 also receives conductors coupled to the doorlight switch within the refrigeration unit 20 via the interconnectingharness allowing a time stamp to be generated when the door of therefrigeration unit 20 is opened and then closed.

The operation of the inventory-tracking unit 30 will now be describedwith particular reference to FIG. 9. When a user wishes to gain accessto the refrigeration unit 20, the user inserts their access card intothe card reader 38. When the card reader 38 detects the inserted card(step 202), the magnetic stripe on the access card is read (step 204)and the read card data is conveyed to the CPU 62 via the databus 66. TheCPU 66 in turn compares the read card data with a list of authorizedusers to determine if the card is valid (step 206). If the read carddata is determined to be invalid, the user is denied access to therefrigeration unit 20. The access card is ejected from the card reader38 (step 208) and the card reader returns to a ready state waiting foranother access card to be inserted therein (step 200). At step 206, ifthe read card data is determined to be valid, the CPU 62 signals thecard reader 38 to lock the access card therein (step 210). The CPU 62also signals the solenoid door lock 40 via the freezer interface 72causing the solenoid door lock to disengage the door of therefrigeration unit 20 (step 212). With the door of the refrigerationunit 20 unlocked, the user is able to open the refrigeration unit 20thereby to gain access to supplies therein.

When the user opens the door of the refrigeration unit and the doorlight switch closes the circuit to illuminate the interior light withinthe refrigeration unit 20, a signal is conveyed to the CPU 62. The CPU62 in turn generates a time stamp using the real-time clock allowing thetime the refrigeration unit 20 is in an open condition to be accuratelytracked. As the user begins removing items from the refrigeration unit20, the tag on each removed item is detected by the internal sensorantenna. The internal sensor antenna in turn signals the CPU 62 via thecommunications interface 84 and databus 66 allowing the CPU 62 tomaintain a count of the removed items (step 222).

When the door of the refrigeration unit 20 is closed, the CPU 62conditions the barcode scanner 34 to a ready state and ends the timestamp (step 224). As a result, the length of time each user maintainsthe refrigeration unit 20 opened can be monitored. Extended door openconditions that may cause undesired temperature changes within therefrigeration unit 20 can also be detected. With the barcode scanner 34enabled, the user is required to pass the removed items beneath thebarcode scanner 34 so that the barcodes on the removed items can bescanned. After each barcode is scanned, the barcode scanner 34 conveysthe scanned barcodes to the CPU 62 allowing the CPU 62 to maintain alist of the scanned items (step 226). When the number of scanned itemsis equal to the removed item count, the CPU 62 signals the solenoid doorlock 40 via the freezer interface 72 causing the solenoid door lock 40to engage the door of the refrigeration unit 20 (step 230). The accesscard is then ejected from the card reader 38 (step 208) and the cardreader returns to a ready state waiting for another access card to beinserted therein (step 200). As will be appreciated, since a count ofremoved items is maintained and compared with the list of scannedbarcodes, accurate transactions involving inventory within therefrigeration unit 20 can be maintained.

After a user has completed a transaction with the refrigeration unit 20,the CPU 62 conveys the scanned barcode information to a remote site overa wireless communication link via the radio interface 70 and one of thetransceivers 74 or 76. In the scenario shown in FIG. 10, theinventory-tracking unit 30 conveys the transaction to a remote site 100over a wireless wide area network 102 via radio interface 70 and WANtransceiver 74. In the scenario shown in FIG. 12, inventory-trackingunits 30 convey transactions to a computer room 104 over a wirelesslocal area network 106 via radio interfaces 70 and LAN transceivers 76.

At the remote site, the received scanned barcode data is stored in adatabase so that an accurate real-time status of the inventory withinthe refrigeration unit 20 can be maintained. The maintenance of accurateinventory information allows useful sales reports to be generated andallows replenishment schedules to be adjusted to conform to inventorydemand. Generated reports are posted on encrypted web pages that can beaccessed by authorized users via Internet connections.

Depending on the environment, the scanned barcode data may be used todebit an account associated with the user. In this case, when the debitvalue of the account reaches a threshold level, the remote sitegenerates a request for funds to zero the debit value. In this manner,the access card functions as both an access and debit card i.e. similarto a smart card.

If at any time, the temperature within the refrigeration unit risesabove the threshold temperature as detected by the thermistor, theinternal sensor antenna in the refrigeration unit 20 signals theinventory-tracking unit 30. In response, the CPU 62 generates an alarmsignal that is used to sound siren 56 and records the alarm event. TheCPU 62 also conveys the alarm event to the remote site over the wirelesscommunications link so that the alarm event can be recorded. The CPU 62also generates and records an alarm event when the door of therefrigeration unit 20 is left open for an extended period of time abovea threshold and when the compressor of the refrigeration unit isbelieved to be approaching its service life. These alarm events are alsorecorded and conveyed to the remote site over the wirelesscommunications link. In this manner service personnel can be quicklydispatched.

If desired, since the internal sensor antenna detects when items areplaced into the refrigeration unit 20, the inventory-tracking unit 30can be programmed to maintain an item count during restocking and conveythe item count to the remote site providing for complete inventorycontrol.

FIGS. 1 and 11 show a small number of inventory-tracking units 30communicating with a remote site. Those of skill in the art willappreciate that this is for illustrative purposes only. In a typicalenvironment, the remote site recieves transactions from a significantnumber of geographically distributed inventory-tracking units 30. Also,the inventory-tracking units may be used with other types of storageunits such as for example vending machines and the like. In the case ofvending machines that securely hold items, the requirement for a doorlocking mechanism is obviated.

Although embodiments of the present invention have been described, thoseof skill in the art will appreciate that variations and modificationsmay be made without departing from the spirit and scope thereof asdefined by the appended claims.

1. An inventory-tracking unit associated with a storage unit holding aplurality of items, said items being openly accessible to a userauthorized to access said storage unit, said inventory-tracking unitcomprising: a card reader to read an access card issued to an authorizeduser; a sensor associated with said storage unit for automaticallysensing removal of each item from said storage unit and generating firstitem identification data for each removed item; a scanner external ofsaid storage unit for subsequently reading data recorded on each itemafter the item has been removed from said storage unit and generatingsecond item identification data; a processor communicating with saidcard reader, sensor and scanner, said processor comparing the first itemidentification data generated by the sensor for each removed item andthe second item identification data read by the scanner from the sameremoved item to detect coincidence, said processor generating atransaction upon coincidence of said first item identification data andsaid second item identification data; and a communications interface totransmit said transaction to a remote computing site.
 2. Theinventory-tracking unit of claim 1, wherein said communicationsinterface transmits said transaction over a wireless communicationslink.
 3. The inventory-tracking unit of claim 1, wherein said scanner isa barcode scanner.
 4. The inventory-tracking unit of claim 1, whereinsaid card reader reads a magnetic stripe on said access card.
 5. Theinventory-tracking unit of claim 1, further including a housingaccommodating said card reader, scanner, processor and communicationsinterface, said housing being coupled to said storage unit.
 6. Theinventory-tracking unit of claim 5, further comprising a lockingmechanism coupled to said storage unit to inhibit access to items heldtherein, said locking mechanism being conditioned by said processor to adisengaged state to permit user access to items held in said storageunit when a valid access card is read by said card reader.
 7. Theinventory-tracking unit of claim 6, wherein said storage unit is arefrigeration unit storing medical supplies, said locking mechanisminhibiting a door of said refrigeration unit from being opened when inan engaged state.
 8. The inventory-tracking unit of claim 7, whereinsaid processor communicates with at least one diagnostic sensorassociated with said storage unit, said processor transmitting an alarmevent to said remote site in response to alarm condition input receivedfrom said at least one diagnostic sensor.
 9. The inventory-tracking unitof claim 8, wherein said at least one diagnostic sensor comprises atemperature sensor monitoring the temperature within said refrigerationunit and generating said alarm condition input when the temperaturewithin said refrigeration unit exceeds a threshold.
 10. Theinventory-tracking unit of claim 1, wherein said storage unit is avending machine.
 11. An inventory-tracking system, comprising: a remotecomputing site; and at least one inventory-tracking unit associated witha storage unit holding a plurality of items, said items being openlyaccessible to a user authorized to access said storage unit, saidinventory-tracking unit comprising: a card reader to read an access cardissued to an authorized user; a sensor associated with said storage unitfor automatically sensing removal of each item from said storage unitand generating first item identification data for each removed item; ascanner external of said storage unit for subsequently reading datarecorded on each item after the item has been removed from said storageunit and generating second item identification data; a processorcommunicating with said card reader, sensor and scanner, said processorcomparing the first item identification data generated by the sensor foreach removed item and the second item identification data read by thescanner from the same removed item to detect coincidence, said processorgenerating a transaction upon coincidence of said first itemidentification data and said second item identification data; and acommunications interface to transmit said transaction to said remotecomputing site.
 12. The inventory-tracking system of claim 11,comprising a plurality of inventory-tracking units at geographicallyspaced locations.
 13. The inventory-tracking system of claim 12, whereinsaid inventory-tracking units communicate with said remote computingsite over a wireless wide area network.
 14. The inventory-trackingsystem of claim 12, wherein said inventory-tracking units communicatewith said remote computing site over a wireless local area network. 15.The inventory-tracking system of claim 12, wherein said scanner is abarcode scanner.
 16. The inventory-tracking system of claim 15, whereinsaid card reader reads a magnetic stripe on said access card.
 17. Theinventory-tracking system of claim 15, further including a housingaccommodating said card reader, scanner, processor and communicationsinterface, said housing being coupled to said storage unit.
 18. Theinventory-tracking system of claim 17, further comprising a lockingmechanism coupled to said storage unit to inhibit access to items heldtherein, said locking mechanism being conditioned by said processor to adisengaged state to permit access to items held in said storage unitwhen a valid access card is read by said card reader.
 19. Theinventory-tracking system of claim 18, wherein said storage unit is arefrigeration unit storing medical supplies, said locking mechanisminhibiting a door of said refrigeration unit from being opened when inan engaged state.
 20. The inventory-tracking system of claim 19, whereinsaid processor communicates with at least one diagnostic sensorassociated with said storage unit, said processor transmitting an alarmevent to said remote computing site in response to alarm condition inputreceived from said at least one diagnostic sensor.
 21. Theinventory-tracking system of claim 20, wherein said at least onediagnostic sensor comprises a temperature sensor monitoring thetemperature within said refrigeration unit and generating said alarmcondition input when the temperature within said refrigeration unitexceeds a threshold.
 22. The inventory-tracking unit of claim 6, whereinsaid processor conditions said card reader to lock said access cardtherein until the first item identification data is coincident with saidsecond item identification data.
 23. The inventory-tracking unit ofclaim 7, wherein said scanner is enabled by said processor upon removalof items from said refrigeration unit and the subsequent closing of saiddoor.
 24. The inventory-tracking unit of claim 7, wherein said processormonitors the elapsed time said refrigeration unit remains opened andgenerates an alarm event when the elapsed time exceeds a threshold. 25.The inventory-tracking system of claim 18, wherein said processorconditions said card reader to lock said access card therein until thefirst item identification data is coincident with said second itemidentification data.
 26. The inventory-tracking system of claim 18,wherein said processor monitors the elapsed time said refrigeration unitremains opened and generates an alarm event when the elapsed timeexceeds a threshold.
 27. A dispensing system, comprising: a storage unitholding a plurality of items, said items being openly accessible to auser authorized to access said storage unit; a card reader to read anaccess card issued to an authorized user; a sensor associated with saidstorage unit for automatically sensing removal of each item from saidstorage unit and generating first item identification data for eachremoved item; a scanner external of said storage unit for subsequentlyreading data recorded on each item after the item has been removed fromsaid storage unit and generating second item identification data; aprocessor communicating with said card reader, sensor and scanner, saidprocessor comparing the first item identification data generated by thescanner for each removed item and the second item identification dataread by the scanner from the same removed item to detect coincidence,said processor generating a transaction upon coincidence of said firstitem identification data and said second item identification data; and acommunications interface to transmit said transaction to a remotecomputing site.